Member for reinforcing, sealing or baffling and reinforcement system formed therewith

ABSTRACT

A member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The member typically includes a carrier member that is typically at least partially formed of a metal. The member also typically includes an expandable material disposed on the carrier member.

CLAIM OF PRIORITY

To the extent applicable, the present invention claims the benefit ofthe priority of U.S. Provisional Application Ser. No. 60/623,099, filedOct. 28, 2004, the contents of which are incorporated by referenceherein.

TECHNICAL FIELD

The present invention relates to a member, which is employed forproviding reinforcing, sealing, baffling, combinations thereof or thelike to a structure of an article of manufacture such as an automotivevehicle. More particularly, the present invention relates to areinforcement member that is at least partially formed of a metal orpolymeric foam (e.g., includes an aluminum foam carrier) or a solidmetal or metal alloy.

BACKGROUND

For many years, industries such as the transportation industry have beeninnovatively designing members for enhancing structural reinforcement,damping, sealing, baffling, thermal insulation and acoustic absorptioncharacteristics of articles such as furniture, buildings andtransportation vehicles (e.g., automotive vehicles, boats, trains,busses, airplanes or the like). Design of such members can involveseveral different considerations, and these considerations may need tobe balanced against one another to achieve a desired result. Examples ofsuch considerations include, without limitation, strength, stiffness,weight, and cost of the members. Other considerations includecompatibility of the members with articles of manufacture, ease ofassembling the members to articles of manufacture, ability of themembers to provide desired levels of damping, reinforcement or sealingor other like considerations.

In the interest of continuing such innovation, the present inventionprovides an improved member suitable for providing baffling, sealing,reinforcing, a combination thereof or the like to a structure of anarticle of manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an exemplary reinforcementmember formed in accordance with an aspect of the present invention.

FIG. 2 illustrates a sectional view of the exemplary reinforcementmember taken along line 2-2.

FIG. 3 illustrates an exemplary application of the reinforcement memberof FIG. 1 to a structure of an automotive vehicle in accordance with anaspect of the present invention.

SUMMARY OF THE INVENTION

A process is employed for reinforcing, sealing or baffling a structure(e.g., a pillar) of an article of manufacture (e.g., an automotivevehicle). The process typically includes formation of a metal materialinto a carrier. Such formation typically includes a thixomoldingprocess, although not required. Preferably the metal material includesaluminum, magnesium or a combination thereof. An expandable material isoften applied to the carrier to form a member for reinforcement,baffling or sealing. The member is then typically inserted within acavity of the structure of the article of manufacture. Thereafter, theexpandable material may be activated to expand, contact and wet internalwalls of the cavity of the structure of the article of manufacture andcured and adhered top the walls of the structure.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon the provision of an improvedmember for sealing, baffling or reinforcing a structure of an article ofmanufacture. The present invention also provides a method of making theimproved member, a method of using the improved member and a systemformed thereby. Although it is contemplated that the member may beemployed in a variety of articles of manufacture, for exemplarypurposes, the member is discussed herein as being employed in anautomotive vehicle. The process for forming the member and for applyingthe member to an automotive vehicle preferably includes one or acombination of the following steps:

-   -   i) providing a metal or polymeric material such as aluminum,        aluminum alloy, aluminum based metal matrix composite,        magnesium, magnesium alloy, nylon, combinations thereof or the        like typically in a molten or partially molten state;    -   ii) shaping (e.g., extruding, casting or molding) the metal        material to form a carrier member wherein the carrier member can        have an internal cellular structure or can be internally solid        and continuous;    -   iii) applying an expandable material to a surface of the carrier        member for forming the member, typically a reinforcement member;    -   iv) placing the member within a cavity of an automotive vehicle,        the cavity being defined by one or more walls of a structure of        the automotive vehicle; and    -   v) activating the expandable material to form a structural foam        that is adhered to the carrier member and the one or more walls        of the structure of the automotive vehicle for forming a        reinforced structural system.

For exemplary purposes, FIGS. 1 and 2 illustrate a reinforcement member10 formed in accordance with an aspect of the present invention. Thereinforcement member 10 includes a carrier member 12 and an expandablematerial 14 disposed upon the carrier member 12.

Material for the Carrier Member

The carrier member is typically formed of a metal material, which mayinclude any metal such as tin, steel, aluminum, magnesium, iron, nickel,copper, cobalt, titanium, Nb, vanadium, zirconium, tungsten, acombination thereof or the like. The carrier member may also be formedof a polymeric material such as polyamide (e.g., nylon). The metalmaterial or the polymeric material may also include a variety ofadditional materials such as fillers, fibers, metal matrix composite(MMC), refractory particles, stabilizers, combinations thereof or thelike. Typically, when metal is employed, the metal material for thecarrier member is at least 70% metal, more typically at least 85% metaland even more typically at least 92% metal. In a preferred embodiment,the metal material is at least 65% aluminum and/or magnesium, moretypically at least 80% aluminum and/or magnesium and even more typicallyat least 90% aluminum and/or magnesium.

As used herein, specification of a metal will typically include thatmetal as well as alloys of that metal, unless otherwise specificallystated. For example, specification of aluminum is meant to include purealuminum and aluminum alloys, unless otherwise stated.

Casting or Molding the Metal Material into the Carrier Member

It is contemplated that the carrier member may be formed, shaped or bothaccording to a variety of techniques such as molding, casting,extruding, stamping, combinations thereof or the like.

Typically, the carrier member can be shaped to have nearly any desiredexternal surface shape and can also be internally shaped for example byusing inserts, which may be removable or non-removable. For exemplarypurposes, the carrier member 12 of FIGS. 1 and 2 has been formed to havean external surface 20 that defines a first concave arcuate surface 22and a second concave arcuate surface 24. Moreover, the external surface20 includes multiple cavities 28 for receiving the expandable material14.

In one embodiment, a metal (e.g., an aluminum) foamed carrier is formedaccording to a process. The process typically includes a combination ofthe following steps:

-   -   i) combining of a particulate foaming agent with a particulate        metal or metal alloy to form a foaming agent/metal admixture;    -   ii) forming masses of the admixture; and    -   iii) molding the masses of the admixture to activate the foaming        agent and form a cellular carrier of a desired shape.

Typically the metal (e.g., steel, aluminum or aluminum alloy or othermetal) is mixed with the foaming agent (e.g., titanium hydride) to forma substantially well mixed or homogeneous metal/foaming agent admixture.Such mixing can be accomplished by supplying the metal and the foamingagent and potentially other ingredients (e.g., steel ball bearings) to acontainer or bin and mixing these components with a mixing device suchas an impeller to form the admixture.

Once formed, the metal/foaming agent admixture is typically furtherprocessed to form several masses (i.e., solid or semi-solid masses) ofthe admixture. As one example, the admixture may be extruded underpressure to form masses (e.g., bars, plate or panel) of the admixture.As another example, the admixture may be roll bonded between metalsheets such as aluminum or steel sheets to form masses (e.g., sandwichstructures) with the admixture held between the sheets.

The masses can then be molded and the foaming agent activated to form acellular or foamed carrier of a desired shape. Typically, the masses ofthe metal/foaming agent admixture are placed within a mold or die havingthe desired shape of the carrier. Thereafter, the admixture is heated(e.g., in an oven or furnace) to a temperature that at least partiallyor substantially entirely melts or softens the metal of the admixtureand, at the same time or at different times, activates the foaming agent(e.g., TiH) to form gas bubbles (e.g., H₂ bubbles) that become entrappedwithin the metal thereby forming a cellular carrier of the desiredshape.

It is contemplated that a skin may be formed on the outer periphery ofthe carrier using any forming techniques described herein by controllingthe cooling of the metal foam within a mold or using one of the othertechniques described herein or elsewhere.

In other embodiments, it is contemplated that the carrier member may beformed of an internally continuous, solid and/or non-cellular material.In one exemplary embodiment, a metal may be die cast to form the carriermember to the desired shaped. In such an embodiment, a metal such asaluminum or magnesium is typically provided in a molten state to a diethat has a shape corresponding to the desired shape of the carriermember. Thereafter, the metal is allowed to cool within the die to forma solid metal carrier.

In another embodiment, an internally solid or continuous carrier memberis formed using a thixomolding process. According to the process, metalmasses (e.g., chips, pellets or the like) are feed to a machine having amolding barrel and a screw. The screw of the machine then advances themasses (e.g., by rotation of the screw) and the masses are at leastpartially softened or melted to form a metal liquid or semi-solid fluid(e.g., a slurry, a liquid, a mixture of liquid and solid or the like).In one particular embodiment, the masses are formed into a slurry ofspherical or otherwise shaped solid particles in a liquid metal matrix.Although, the spherical or otherwise solid particles are typicallyinternally solid, it is contemplated that the spherical or otherwiseshaped solid particles may be hollow for forming a cellular carriermember.

Once formed, the metal fluid is fed to or injected within a cavity of amold at a temperature of between about 150-400° C. and more typicallybetween about 200-250° C., although higher or lower temperatures may beemployed depending upon the metal or metal mixture being shaped.Typically, the cavity is in the desired shape of the carrier member. Themetal fluid then solidifies to form a carrier member in a desired shapeand/or configuration.

Generally, thixomolding processes, materials for thixomolding,thixomolding equipment and the like are disclosed in U.S. Pat. Nos.6,736,188; 6,514,309; 6,514,308; 6,299,665; 6,059,012; 5,996,679;5,983,978; 5,819,839; 5,711,366; all of which are incorporated herein byreference for all purposes.

In yet another embodiment, it is contemplated that a polymer materialmay be injection molded or otherwise molded to form a solid or cellularcarrier member of desired shape. One exemplary method of forming acellular polymeric carrier is disclosed in copending application serialno. 10/686,845, filed October 16, 2003, which is incorporated herein byreference for all purposes.

Generally it is contemplated that the outer surface of the carrier mayinclude or be roughened or textured for allowing the expandable materialto adhere to the surface with greater strength. In one embodiment, thedie or mold may be roughened or textured such that the carrier, the skinor both having a corresponding roughness or texture upon formation ofthe carrier. In another embodiment, the carrier may be formed or shapedand the outer surface may be subsequently roughened (e.g., by sanding orother technique).

Applying Expandable Material to the Carrier Member to Form aReinforcement Member

When used in automotive vehicles or other articles of manufacture, it ispreferable for an expandable material to be applied to the carriermember of the invention for forming a reinforcement member or a memberfor sealing or baffling. In FIGS. 1 and 2, the expandable material 14 isdisposed upon the outer surface 20 of the carrier member 12 for formingthe reinforcement member 10. In particular, the expandable material 14is at least partially disposed within the cavities 28 formed in thecarrier member 12. It is contemplated, however, that the expandablematerial may be placed in nearly any configuration upon any surface ofany carrier member formed in accordance with the present invention.

The expandable material may be formed of several different materials.Generally speaking, the member may utilize technology and processes forthe forming and applying the expandable material such as those disclosedin U.S. Pat. Nos. 4,922,596, 4,978,562, 5,124,186, and 5,884,960 andcommonly owned, co-pending U.S. application Ser. No. 09/502,686 filedFeb. 11, 2000 and U.S. applicaiton Ser. No. 09/524,961 filed Mar. 14,2000, and U.S. Application attorney docket no. 1001-141, filed Jun. 15,2004, all of which are expressly incorporated by reference for allpurposes. Typically, when used for reinforcement, the expandablematerial is formed of a high compressive strength and stiffness heatactivated reinforcement material having foamable characteristics. Thematerial may be generally dry to the touch or tacky and can be placedupon the carrier member or the like in any form of desired pattern,placement, or thickness, but is preferably of substantially uniformthickness. One exemplary expandable material is L-5204 structural foamavailable through L&L Products, Inc. of Romeo, Mich.

Though other heat-activated materials are possible for the expandablematerial, a preferred heat activated material is an expandable polymeror plastic, and preferably one that is foamable. A particularlypreferred material is an epoxy-based structural foam. For example, andwithout limitation, the structural foam may be an epoxy-based material,including an ethylene copolymer or terpolymer that may possess analpha-olefin. As a copolymer or terpolymer, the polymer is composed oftwo or three different monomers, i.e., small molecules with highchemical reactivity that are capable of linking up with similarmolecules.

A number of epoxy-based structural reinforcing or sealing foams areknown in the art and may also be used to produce the structural foam. Atypical structural foam includes a polymeric base material, such as anepoxy resin or ethylene-based polymer which, when compounded withappropriate ingredients (typically a blowing and curing agent), expandsand cures in a reliable and predicable manner upon the application ofheat or the occurrence of a particular ambient condition. From achemical standpoint for a thermally-activated material or a thermosetmaterial, the structural foam is usually initially processed as aflowable thermoplastic material before curing. Such a material willtypically cross-link upon curing, which makes the material incapable offurther flow.

An example of a preferred structural foam formulation is an epoxy-basedmaterial that is commercially available from L&L Products of Romeo,Mich., under the designations L5206, L5207, L5208, L5209. One advantageof the preferred structural foam materials over prior art materials isthat the preferred materials can be processed in several ways. Thepreferred materials can be processed by injection molding, extrusioncompression molding or with a mini-applicator. This enables theformation and creation of part designs that exceed the capability ofmost prior art materials. In one preferred embodiment, the structuralfoam (in its uncured state) generally is dry or relatively free of tackto the touch and can easily be attached to the carrier member throughfastening means which are well known in the art.

While the preferred materials for fabricating the expandable materialhave been disclosed, the expandable material can be formed of othermaterials provided that the material selected is heat-activated orotherwise activated by an ambient condition (e.g. moisture, pressure,time or the like) and cures in a predictable and reliable manner underappropriate conditions for the selected application. One such materialis the epoxy based resin disclosed in U.S. Pat. No. 6,131,897, theteachings of which are incorporated herein by reference, filed with theU.S. Patent and Trademark Office on Mar. 8, 1999 by the assignee of thisapplication. See also, U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526;and 5,932,680, (incorporated by reference). In general, the desiredcharacteristics of the expandable material include relatively highstiffness, high strength, high glass transition temperature (typicallygreater than 70 degrees Celsius), and adhesion durability properties. Inthis manner, the material does not generally interfere with thematerials systems employed by automobile manufacturers. Exemplarymaterials include materials sold under product designation L5207 andL5208, which are commercially available from L & L Products, Romeo,Mich.

It is also contemplated that, when the member of the present inventionis used for sealing or baffling, the expandable material may be designedto absorb or attenuate sound, block off and prevent passage of materialsthrough a cavity or the like. As such, the expandable material may beconfigured to expand to greater than a volume that is at least 200%, atleast 400%, at least 800%, at least 1600% or even at least 3000% or itsoriginal unexpanded volume. Examples of such expandable material arediscussed in U.S. Application attorney docket no. 1001-141, filed Jun.15, 2004, expressly incorporated by reference.

In applications where the expandable material is a heat activated,thermally expanding material, an important consideration involved withthe selection and formulation of the material comprising the structuralfoam is the temperature at which a material reaction or expansion, andpossibly curing, will take place. For instance, in most applications, itis undesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the structural foam becomes reactive at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the foam is processed along with the automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during paint curing steps. While temperatures encountered in anautomobile assembly operation may be in the range of about 148.89° C. to204.44° C. (about 300° F. to 400° F.), body and paint shop applicationsare commonly about 93.33° C. (about 200° F.) up to about 193° C. (about380° F.) or higher. If needed, blowing agent activators can beincorporated into the composition to cause expansion at differenttemperatures outside the above ranges.

Generally, suitable expandable foams have a range of expansion rangingfrom approximately 0 to over 1000 percent. The level of expansion of theexpandable material 30 may be increased to as high as 1500 percent ormore. Typically, strength and stiffness are obtained from products thatpossess lower expansion.

Some other possible materials for the expandable material include, butare not limited to, polyolefin materials, copolymers and terpolymerswith at least one monomer type an alpha-olefin, phenol/formaldehydematerials, phenoxy materials, and polyurethane. See also, U.S. Pat. Nos.5,266,133; 5,766,719; 5,755,486; 5,575,526; 5,932,680; and WO 00/27920(PCT/US 99/24795) (all of which are expressly incorporated byreference). In general, the desired characteristics of the resultingmaterial include relatively low glass transition point, and goodadhesion durability properties. In this manner, the material does notgenerally interfere with the materials systems employed by automobilemanufacturers. Moreover, it will withstand the processing conditionstypically encountered in the manufacture of a vehicle, such as thee-coat priming, cleaning and degreasing and other coating processes, aswell as the painting operations encountered in final vehicle assembly.

In another embodiment, the expandable material is provided in anencapsulated or partially encapsulated form, which may comprise apellet, which includes an expandable foamable material, encapsulated orpartially encapsulated in an adhesive shell. An example of one suchsystem is disclosed in commonly owned, co-pending U.S. application Ser.No. 09/524,298 (“Expandable Pre-Formed Plug”), hereby incorporated byreference.

In addition, as discussed previously, preformed patterns may also beemployed such as those made by extruding a sheet (having a flat orcontoured surface) and then die cutting it according to a predeterminedconfiguration in accordance with the chosen pillar structure, door beam,carrier member or the like, and applying it to thereto.

The skilled artisan will appreciate that the system may be employed incombination with or as a component of a conventional sound blockingbaffle, or a vehicle structural reinforcement system, such as isdisclosed in commonly owned co-pending U.S. application Ser. Nos.09/524,961 or 09/502,686 (hereby incorporated by reference).

It is contemplated that the material of the expandable material could bedelivered and placed into contact with the assembly members, through avariety of delivery systems which include, but are not limited to, amechanical snap fit assembly, extrusion techniques commonly known in theart as well as a mini-applicator technique as in accordance with theteachings of commonly owned U.S. Pat. No. 5,358,397 (“Apparatus ForExtruding Flowable Materials”), hereby expressly incorporated byreference. In this non-limiting embodiment, the material or medium is atleast partially coated with an active polymer having dampingcharacteristics or other heat activated polymer, (e.g., a formable hotmelt adhesive based polymer or an expandable structural foam, examplesof which include olefinic polymers, vinyl polymers, thermoplasticrubber-containing polymers, epoxies, urethanes or the like) wherein thefoamable or expandable material can be snap-fit onto the chosen surfaceor substrate; placed into beads or pellets for placement along thechosen substrate or member by means of extrusion; placed along thesubstrate through the use of baffle technology; a die-cast applicationaccording to teachings that are well known in the art; pumpableapplication systems which could include the use of a baffle and bladdersystem; and sprayable applications.

Installing the Reinforcement, Sealing or Baffling Member To anAutomotive Vehicle

Once completed, the reinforcement sealing or baffling member of thepresent invention is preferably installed to an automotive vehiclealthough it may be employed for other articles of manufacture such asboats, buildings, furniture, storage containers or the like. The membermay be used to reinforce, seal or baffle a variety of components of anautomotive vehicle including, without limitation, body components (e.g.,panels), frame components (e.g., hydroformed tubes), pillar structures(e.g., A, B or C-pillars), bumpers, roofs or the like of the automotivevehicle.

In one preferred embodiment, the reinforcement, sealing or bafflingmember is placed at least partially within a cavity of a structure of anautomotive vehicle wherein the cavity is defined by one or more walls orsurfaces of the structure. Thereafter, the expandable material isactivated to expand, wet, and adhere to one or more surfaces of thecarrier member and one or more surfaces of the component of theautomotive vehicle. Upon curing, the expandable material preferablyforms a rigid structural or sealing or baffling foam securing thereinforcement member within the cavity of the structure of the vehiclethereby reinforcing the structure.

According to one exemplary embodiment shown in FIG. 3, there isillustrated the exemplary reinforcement member 10 that includes thecarrier member 12 with the expandable material 14 disposed thereon. Asshown, the reinforcement member 10 is suitable for placement adjacent toa structure 40 (e.g., a pillar structure) or within a cavity 42 of thestructure 40, which is preferably a structure of an automotive vehicle.In the embodiment shown, the structure 40 has a cavity 42 correspondingto the configuration, particularly the outer surface 20, of the carriermember 12, the reinforcement member 10 or both. However, it shall beunderstood that the structure 40 may be formed in nearly any shape orconfiguration depending upon the intended use of the member 10 anddepending upon other factors.

The carrier member 12, the reinforcement member 10 or both extend alongan axis extending the length of the carrier member 12. The expandablematerial 14 in the particular embodiment illustrated is divided intomultiple (e.g., four) masses 48 each disposed within one of the multiplecavities 28 of the carrier member 12 and extending lengthwise thereon.

The reinforcement member 10 may be inserted within the cavity 42 of thestructure 40 in separate parts or as a unit. Upon insertion, the outersurface 20 of the carrier member 12, of the reinforcement member 10 orboth are preferably adjacent and substantially opposing walls 50defining the cavity 42, although not required. It should be understoodthat various supports or fasteners such as mechanical fasteners,adhesives, magnets, combinations thereof or the like, which may beintegral with or attached to the reinforcement member and may beutilized to assist in locating the reinforcement member within thecavity at least until the expandable material is expanded and cured.

After insertion, the masses 48 of expandable material 14 are preferablyactivated as described herein to expand, contact and wet the walls 50 ofthe structure 40 and cure to adhere the reinforcement member 10, thecarrier member 12 or both to the walls 50 of the structure 40 therebyforming a reinforced structural system. Advantageously, thereinforcement member 10 in this manner provides structural integrity tothe structure 40 of the automotive vehicle.

In certain embodiments, it is contemplated that, prior to activation,measures may be taken to provide clearance between the reinforcementmember and the walls of the structure into which the reinforcementmember is placed. For example, the reinforcement member may be providedwith spacers (e.g., small extensions), which are designed to maintainspace between the walls and the reinforcement member prior toactivation. Alternatively, portions of the expandable material may beplaced or shaped such that those portions act as spacers. In thismanner, e-coat can more easily coat the walls defining the cavity priorto activation of the expandable material.

It is also generally contemplated that the expandable material may belocated upon the carrier member such that the carrier member and thewalls of the cavity do not significantly contact each other. Forexample, the carrier may be substantially or fully encapsulated in theexpandable material such that, upon activation, the expanded expandablematerial (i.e., the structural foam) provides a barrier between thecarrier and the wall. Alternatively, the expandable material may belocated such that, upon expansion, the expandable material spaces thecarrier member away from the walls such that there is minimal contacttherebetween. In this manner, any potential undesirable reactions (e.g.,galvanic reactions or corrosive reactions), which might otherwise takeplace between the walls and the carrier, particularly when the walls andcarrier are of dissimilar metals (e.g., where the structure is steel orferrous and the carrier includes aluminum), can be avoided.

While the exemplary drawings of the invention feature a reinforcementmember, it is contemplated that the skilled artisan will be able to formsealing or baffling members by shaping or configuring carrier membersand expandable materials in known shapes and configurations, but usingforming techniques described herein. Exemplary sealing and bafflingmembers are disclosed in copending application Ser. No. 10/847,016,filed May 17, 2004; Ser. No. 10/941,553, filed Sep. 15, 2004; Ser. No.10/686,845, filed Oct. 16, 2003 and Ser. No. 10/617,058, filed Jul. 10,2003, all of which are incorporated herein by reference for allpurposes.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A process for reinforcing, sealing or baffling a structure of anarticle of manufacture, the process comprising: forming a metal materialinto a carrier, the metal material including aluminum, magnesium or acombination thereof; applying an expandable material to the carrier toform a member; inserting the member within a cavity of the structure;and activating the expandable material to expand, contact and wetinternal walls of the cavity of the structure of the article ofmanufacture and to adhere the member within cavity.
 2. A process as inclaim 1 wherein the forming of the metal material includes shaping of aslurry of spherical or otherwise shaped solid particles in a liquidmetal matrix.
 3. A process as in claim 1 wherein the forming of themetal material includes a thixomolding process.
 4. A process as in claim1 wherein the structure is part of an automotive vehicle.
 5. A processas in claim 1 wherein the metal material of the carrier is at least 85%metal.
 6. A process as in claim 1 wherein the carrier member has anouter surface that is roughened or textured for allowing the expandablematerial to adhere to a surface of the carrier with greater strength. 7.A process as in claim 1 wherein the shape of the carrier corresponds tothe shape of the cavity of the structure.
 8. A process as in claim 1wherein the expandable material is activated at a temperatureexperienced in an e-coat or paint oven.
 9. A process for reinforcing astructure of an automotive vehicle, the process comprising: forming ametal material into a carrier, the metal material including aluminum,magnesium or a combination thereof, the forming of the carrierincluding: i. forming metal masses into a slurry of solid particles in aliquid metal matrix; ii. feeding the slurry within a cavity of a mold;iii. solidifying the slurry within the mold to form the carrier into adesired shape applying an expandable material to the carrier to form areinforcement member; inserting the member within a cavity of thestructure; and activating the expandable material to expand, contact andwet internal walls of the cavity of the structure of the article ofmanufacture and to adhere the member within cavity.
 10. A process as inclaim 9 wherein the solid particles or internally hollow for forming acellular carrier member.
 11. A process as in claim 9 wherein the mold isat a temperature of about 150° C. to abut 400° C.
 12. A process as inclaim 9 wherein the mold is at a temperature of about 200°0 C. to abut250° C.
 13. A process as in claim 9 wherein the forming of the metalmasses into a slurry involve feeding the metal masses to a machinehaving a molding barrel and screw for at least partially melting themetal masses.
 14. A process as in claim 9 wherein the forming of themetal material includes shaping of a slurry of spherical or otherwiseshaped solid particles in a liquid metal matrix.
 15. A process as inclaim 9 wherein the forming of the metal material includes athixomolding process.
 16. A process as in claim 9 wherein the structureis part of an automotive vehicle.
 17. A process as in claim 9 whereinthe metal material of the carrier is at least 85% metal.
 18. A processas in claim 9 wherein the carrier member has an outer surface that isroughened or textured for allowing the expandable material to adhere toa surface of the carrier with greater strength.
 19. A process as inclaim 9 wherein the shape of the carrier corresponds to the shape of thecavity of the structure.
 20. A process as in claim 9 wherein theexpandable material is activated at a temperature experienced in ane-coat or paint oven.